Method and apparatus for the production of flock-coated sheet material



Sept. 8, 1959 J. P. DONAHUE METHOD AND APPARATUS FOR THE PRODUCTION OFFLOCK-COATED SHEET MATERIAL Filed Nov. 5, 1956 9w R W m e m \w m M m %FAWM 3% m 0 2w m m Y B United States Patent METHOD AND APPARATUS FOR THEPRODUC- TION 0F FLOCK-COATED SHEET MATERIAL John P. Donahue, Hawthorne,NJ assignor, by mesne assignments, to D. 8: S. Processing Company, Inc.,Clifton, N.J., a corporation of Delaware Application November '5, 1956,Serial No. 620,247

Claims. (Cl. 11720) The present invention relates to the production ofpilesurfaced or coated materials and, more particularly relates toapparatus for and methods of coating sheet material with flock, tinselor other particles. using sonic or supersonic compression-waves tovibrate the sheet material and the particles applied thereto during thecoating process.

Pile surfaced, flocked, or other particle-coated materials are atpresent commonly manufactured by first coating the surface of the basematerial with an adhesive or by printing particle retaining designsthereon and by thereafter applying flock or other particles to the basematerial while vibrating the base material with mechanical beaters. Theuse of these heaters is effective in embedding flock fibers or otherparticles firmly in the adhesive or printed coating with a generallyupstanding pattern with respect to the base material. However, the operation of the heaters to vibrate the material is accompanied byobjectionable frictional contact between the heaters and the basematerial which causes wear and strain on the base material. Themechanical beating also requires a relatively large amount of power andis accompanied by an objectionable over-all vibration of the coatingapparat us.

The present invention reduces these objectionable effects byaccomplishing the vibration of the adhesively coated flexible materialor web by a compression-wave generator, such as a sonic or super-sonicwave generator.

Accordingly, an object of the. present invention is to provide animproved method and means forforming pilesurfaced materials or materialscoated with abrasive particles or other relatively minute particles.

Another object of the present invention is to provide a method and meansfor vibrating the base material in the manufacture of flocked or coatedgoods in which the mechanical heaters are eliminated.

Another object of the present invention is to provide a method and meansof flocking or coating in which the about to be described, or will beindicated in the appended claims, and various advantages not referred toherein will occur to one skilled in the art upon employment of theinvention in practice.

noise level and over-all vibration of the apparatus are re A preferredembodiment of: the invention has been chosen for purposes ofillustration and description and is .shown in the accompanying drawings,forming a part of the specification, wherein:

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Fig. 1 is a diagrammatic side elevational view of the apparatusembodying the principles of the invention;

Fig. 2 is a top plan viewpartially cut away showing the apparatus ofFig. l;

Fig. 3 is an end elevational View partially cut away of the apparatus ofFig. l; and

Fig. 4 is an enlarged fragmentary sectional view of the upper portion ofthe vibrator mechanism showing the attachment of the flexible diaphragmat the edge of the vibrator frame and the diaphragm tension adjustor.

The method and apparatus will first be described in general withparticular reference to Fig. 1. Fig. l illustrates a preferredembodiment of the flocking apparatus 1 comprising a vibrating means 2above which the flexible sheet material 4 is moved between a supplyroller 5 and a drying or other web handling means (not shown). The basesheet material 4 is carried over the vibrator means 2 from the supplyroller 5 on suitable rollers 8, 9, 10, and 11, and it has an adhesivecoating applied to its upper surface by an adhesive applicator 6containing a supply of suitable. adhesive 7. Any of the well-knownadhesive applicators or base material printing means or stencils may beused in place of the applicator 6 illustrated in Fig. 1. One or more ofthe rollers 8, 9, 10, and 11 may be driven by a suitable drive mechanismso that the sheet material 4 is moved continuously from the supplyroller 5 through the ahesive applicator 6, and above the upper surfaceof the vibrating means 2. Flock fibers 14 are applied to the adhesivelycoated surface of the web 4 as it reaches vibrating means 2 from asuitable flock hopper indicated at 15. Any of the commonly used flock orparticle applying means may be used to supply an even and controlledamount of flock 14 to the adhesive 7 on the web surface.

As the web- 4 passes above the top of the vibrating means 2, thevibrating means imparts a generally vertical vibratory motion to it, aswill be more fully described below in connection with a more detaileddescription of the vibrating means 2. This vibratory motion of the web 4causes the flocked fibers 14 to be implanted in the adhesive 7. By thetime web 4 has reached the righthand end of vibrating means 2, it has auniformly coated surface of planted fibers or other particles 14. Thecoated material 4 is thereafter carried by suitable rollers, such asrollers 10 and 11, from the vibrating means 2 to a suitable storage ordrying means (not shown) where the drying of the adhesive or printedcoating 7 locks the implanted fibers. or particles 14 in position.

A preferred embodiment of the vibrating apparatus is shown in Figs. 1through 3. A plurality of compression-wave generators 24 are mounted inspaced relationship in a vibrator frame 20. The generators 24 may besuitable loud speakers such as electromagnetic or electrodynamicspeakers or other electrically driven vibrators of the well-known types.It is preferred to use generators which have a relatively broadfrequency response, so that they may be driven by a suitable variablefrequency electric-wave generator or oscillator 27 at differentfrequencies for different materials and operating conditions to maintainthe. maximum operating efliciency.

As seen in Fig. 1, a plurality of generators 24 may be wired in parallelby wiring 26 to a suitable oscillator 27. Control of the outputamplitude of the compression-wave generators may be obtained bycontrolling the output level of the oscillator 27, or individual volumecontrols such as are indicated at 37 may be inserted in the individuallead lines to the generators 24 so that the vibratory pattern over thesurface of the vibrating means 2 may be controlled as desired by theadjustment of the output of each of the individual generators 24.

Such a volume control may consist of a variable resistor which isadjustable between a suitable high value and zero. Additional control ofthe vibratory pattern over the surface of the vibrating means 2 may beobtained by inserting a conventional phase control device into one ormore of the individual speaker lead lines such as are indicated at 38 inFig. 1. Such a phase control may be made adjustable for phase shiftsbetween zero and a suitable maximum.

As illustrated in Fig. 1, the preferred location for the web 4 is abovethe upper surface of the vibrating means 2. The upper surface of theframe of the vibrating means 2 is also preferably covered with aflexible diaphragm member 22 such as a sheet of rubber or other flexiblematerial. The diaphragm 22 is tacked or otherwise fastened to the outeredges 21 of the frame 20. The flexible diaphragm 22 has a resonantfrequency at which it will give the maximum vibratory response when thegenerators 24 are operated at that frequency. The vibrator means 2 isoperated most efliciently at or near this resonant frequency. Theresonant frequency of the flexible diaphragm 22 is made adjustable byproviding an adjustable tensioning means therefor. As seen in Fig. 4,the side pieces 21 of frame 20 are connected to end pieces 21a by arotatable screw fastener 21b so that rotation of screw fastener 21bvaries the spacing between side pieces 21 to change the tension offlexible diaphragm 22. The web 4 in the preferred embodiment is spacedabout half an inch from the diaphragm 22. An air cushion is thereforeprovided between the web 4 and the diaphragm 22. The compression-wavesfrom the generators 24 vibrate the web 4 through the intermediation ofthe vibratory motion of the diaphragm 22 and the air cushion existingbetween diaphragm 22 and web 4.

In order to provide for an even distribution of the flocked fibers 14 onthe adhesively coated surface of the web 4, it has been foundadvantageous to oscillate the compression-wave generators 24 laterallyof the direction of the web motion.

As seen in Fig. 3, the generators 24 are mounted on a movable generatormounting panel 25 which has rollers 28 on its lower surface which run intracks 29. A continuous oscillating or reciprocating motion is impartedto the generator mounting panel 25 by a drive system 30. Drive system 30comprises a drive motor 31 coupled to an adjustable speed reducer 32.Speed reducer 32 drives a crank member through the intermediation ofpulleys 33 and 34 and drive belt 36. Crank 35 is pivotally connected atone end to pulley 34 and at its other end to the generator mountingpanel 25 so that rotation of the pulley 34 causes generator mountingpanel 25 to oscillate on tracks 29 transversely of the path of the web4.

The operation of the preferred embodiment of the present invention,which has been disclosed in detail in connection with the abovedescription, may be summarized as follows. The flexible base material orweb 4 is fed from the roller 5 over rollers 8, through the adhesiveapplicator 6, and above the upper surface of the vibrating means 2 onrollers 9, 10, and 11. Suitable drive means connected to one or more ofthe rollers 8, 9, 10, and 11 moves the web 4 continuously along thispath. The flock applicator 15 which is filled with flocked fibers 14applies an even coat of the flock fibers 14 to the adhesively coatedsurface of web 4. Oscillator 27 is energized when the adhesively coatedweb starts to move over vibrator means 2 so that the generators 24vibrate the web 4 through the intermediation of the flexible diaphragm22 and the air cushion between the diaphragm 22 and the web 4. Drivemotor 31 is simultaneously energized so that the drive system 30oscillates the generators 24 transversely of the moving web to providefor an even distribution of the flock fibers 14. As the web 4 with itscoating of adhesive 7 and the flocked fibers 14 superimposed thereonmoves above type of motion which is imparted to each of the flockedfibers causes one end of each fiber to be implanted in the adhesive 7 sothat the fibers orient themselves in a generally uniform verticallyoriented pattern, such as is seen at the right-hand side of Fig. 4,before the web 4 reaches the right-hand end of the vibrating means 2.Thereafter, the flocked or pile surface of the web is carried by rollers10 and 11 to suitable storage and drying means where the adhesive 7dries to hold the flocked fibers 14 in position. Suitable adjustments ofvibration amplitude and phasing are made by means of the oscillatoroutput controls and the volume phasing controls 37 and 38, respectively,to obtain an even and dense distribution of the flocked fibers 14.

While the above disclosure describes and illustrates the flockingoperation in connection with compressionwave generators of theloud-speaker type, operated at sonic or super-sonic frequencies, it isclear that other forms of pressure-wave generators may be used toproduce sonic or super-sonic pressure or compression waves adjacent tothe diaphragm 22. The waves generated by the generators 24 in the airsurrounding the diaphragm 22, web 4, and flock 14 are progressivelongitudinal vibratory disturbances comprising condensations andrarefactions of the air. These are commonly referred to as sound waveswhere they are generated at sonic frequencies. In the present disclosureand claims these types of waves at both sonic and supersonic frequenciesare termed compression waves and the generators are termed compressionwave generators, for convenience.

Although fiber planting can be accomplished with the web 4 contactingthe diaphragm 22, greatly improved results in operating et'ticiencesresult when the web 4 is spaced slightly from the diaphragm 22 asdescribed above.

It will be seen that the present invention provides an improved methodof vibrating the base material in a pile surface coating operation. Themethod and device disclosed reduce wear and over-all vibration of theflocking apparatus and in addition provide an eflicient vibratory systemwhich is more flexible in use and more easily controlled and adjustedthan the conventional mechanical types.

As various changes may be made in the form, construction and arrangementof the parts herein without departing from the spirit and scope of theinvention and without sacrificing any of its advantages, it is to beunderstood that all matter herein is to be interpreted as illustrativeand not in a limiting sense.

Having thus described my invention, I claim:

1. In the manufacture of flock-coated sheet material, the improvedmethod which comprises applying an adhesive coating to a surface of thesheet material, moving the sheet material past a generally horizontalflat flexible diaphragm along a path parallel to and slightly spacedtherefrom, applying elongated flock particles to the adhesive coating,and generating compression waves adjacent to and directed toward thediaphragm and moving in a direction generally perpendicular theretowhereby the diaphragm and the sheet material are vibrated by thecompression waves in a direction perpendicular to the plane of thediaphragm and the sheet material and the elongated flock fibers areimplanted in the adhesive and are oriented generally vertically of thesheet material.

2. The method as claimed in claim 1 which further comprises moving thesource of the compression Waves transversely of the direction of motionof the sheet material to equalize the amplitude of the vibrationstransversely across the sheet material.

3. A device for flock printing sheet material which comprises means tocontinuously coat the sheet material with a layer of adhesive, means toapply flock to the coated surface of the sheet material, means tocontinuously move the adhesively coated sheet material as a relativelyflat sheet along a generally horizontal path bethe vibrating means 2,the generally vertical vibratory neath the flock applying means wherebythe flock engages and adheres to the adhesive, a flat flexible diaphragmbeneath said sheet material and generally parallel thereto and slightlyspaced therefrom, means adjacent said diaphragm to generate compressionwaves directed toward said diaphragm and traveling in a directiongenerally perpendicular to the plane of the sheet whereby the adhesivelycoated textile is vibrated to embed the flock in the adhesive.

4. The device as claimed in claim 3 which further comprises a movablemounting for said means to generate compression waves and a drive meansoperatively connected thereto and adapted to move said means to generatecompression waves transversely of the moving sheet 15 2,748,746

material.

References Cited in the file of this patent UNITED STATES PATENTS1,318,740 Fessenden Oct. 14, 1919 2,020,319 King Nov. 12, 1935 2,337,569Pietschack Dec. 28, 1943 2,657,668 Maier Nov. 3, 1953 2,696,445 Schwartzet al. Dec. 7, 1954 Wommelsdorf June 5, 1956 UNITED STATES PATENT OFFICECERTIFICATE OF CORRECTION Patent No 2,903,376 September 8, 1959 John P.Donahue It is hereby certified that error appears in the printedspecification of the above numbered patent requiring correction and thatthe said Letters Patent should read as corrected below.

Column 5 line 1, strike out "the vibrating means 2, the generallyvertical vibratory" and insert the same between lines 1 and 2, in columnSigned and sealed this 22nd day of March 1960,,

(SEAL) Attest:

KARL AXLINE ROBERT C. WATSON Attesting Ofiiccr Commissioner of Patents

1. IN THE MANUFACTURE OF FLOCK-COATED SHEET MATERIAL, THE IMPROVED METHOD WHICH COMPRISES APPLYING AN ADHESIVE COATING TO A SURFACE OF THE SHEET MATERIAL, MOVING THE SHEET MATERIAL PAST A GENERALLY HORIZONTAL FLAT FLEXIBLE DIAPHRAGM ALONG A PATH PARALLEL TO AND SLIGHTLY SPACED THEREFROM, APPLYING ELONGATED FLOCK PARTICLES TO THE ADHESIVE COATING, AND GENERATING COMPRESSION WAVES ADJACENT TO AND DIRECTED TOWARD THE DIAPHRAGM AND MOVING IN A DIRECTION GENERALLY PERPENDICULAR THERETO WHEREBY THE DIAPHRAGM AND THE SHEET MATERIAL ARE VIBRATED BY THE COMPRESSION WAVES IN A DIRECTION PERPENDICULAR TO THE PLANE OF THE DIAPHRAGM AND THE SHEET MATERIAL AND THE ELONGATED FLOCK FIBERS ARE IMPLANTED IN THE ADHESIVE AND ARE ORIENTED GENERALLY VERTICALLY OF THE SHEET MATERIAL. 